Metal/Polymer Composites

261 Pages·1990·4.291 MB·English

by  John Delmonte (auth.)

METAL/POLYMER
COMPOSITES
METAL/POLYMER
COMPOSITES
John Delmonte
Delsen Testing Laboratories
Glendale, California
~
SPRINGER SCIENCE+BUSINESS MEDIA, LLC
Copyright © 1990 Springer Science+Business Media New York
Origina11y published by Van Nostrand Reinhold 1990
Softcover reprint of the hardcover 1s t edition 1990
Library of Congress Catalog Card Number 89-30815
ISBN 978-1-4684-1448-6 ISBN 978-1-4684-1446-2 (eBook)
DOI 10.1007/978-1-4684-1446-2
AII rights reserved. No part of this work covered by the copyright hereon may be reproduced or
used in any form or by any means-graphic, electronic, or mechanical, inc\uding photocopying,
recording, taping, or information storage and retrieval systems-without written permission of
the publisher.
16 15 14 13 12 II 10 9 8 7 6 5 4 3 2 I
Library of Congress Cataloging-in-Publication Data
Delmonte, John
Metal-polymer composites / John Delmonte.
p. cm.
Inc\udes index.
1. Metallic composites. 2. Polymeric composites. 1. Title.
T A481. D45 1989 89-30815
620.1' 18--dc19 CIP
To Those Individuals Whose Vision
Extends Beyond the Horizon
PREFACE
The growth of composites is most evident when comparing materials of the
early 1960s with materials currently being developed, and their applications.
In a book on metal-filled plastics, which I published in 1961, the focus was
upon combinations of finely divided metals with synthetic resins. Although
such combinations continue to be employed, the available materials, both met
als and polymers, have not only increased dramatically, but the techniques of
effecting combinations have become more sophisticated. Vacuum deposition,
ion implantation and chemical deposition, for example, have supplemented
mechanical blending. As a consequence, consumer electronics in the guise of
magnetic tapes and semiconductive materials is opening new horizons for metal!
polymer composites, in areas which were little known twenty-five years ago.
Continuing research in thin film technology and semiconductors are in some
instances concerned with molecular electronics, where the behavior of mate
rials no longer follows patterns characteristic of macrostructures. Photopoly
mers and their applications as photoresist coatings on semiconductors aremaking
possible new developments in the nanostructures of microelectronic devices.
Large scale applications of metal/polymer composites are now commerically
viable in the automotive, aerospace and aircraft industries. Advanced compos
ites used in these fields include not only new metallic alloys, but also fibrous
reinforcements of glass, silicon-carbide, graphite, polyaramids, aluminum ox
ide, silicon carbide, fine metal fibers and metal whiskers, metal-coated polymer
fibers and flakes. New developments reflect the manufacturing ingenuity of the
United States and Japan as well as the contribution from Great Britain and
West Germany. The author has decided to recognize some of these activities
by drawing attention to recent patent developments and recent technical papers
which underscore the wavefront of continuing technology.
The expanding role of metal powders, which are adapting some plastics
manufacturing techniques to the fabrication of powder metal compacts is cov
ered in the early chapters. New amorphous metal compounds formed by rapid
cooling solidification processes, extend the rapport between metals and poly
mers.
Many individuals have contributed suggestions and ideas which appear in
vii
viii METAL/POLYMER COMPOSITES
this book and, to these individuals, I express my gratitude. In particular, I
wish to acknowledge Dr. Jack Ching and Lee McCrory, president of Delsen
Testing Laboratory, both of whom reviewed some chapters, and to Professor
Robert Grubbs of the California Institute of Technology who reviewed Chapter
4 on electroconductive metal/polymer composites. I am also grateful for help
ful suggestions by Raymond Seymour, Distinguished Professor of Polymer
Science, particularly for Chapter 5 on coatings. I have drawn upon my diverse
experience on materials over a period of fifty years, and any mistakes that may
have been introduced are my personal responsibility. The patience and help of
Bonnie Sidewell and Jacquie Thibault in the typing and retyping of a compli
cated manuscript are gratefully acknowledged. To my wife, Janet, my loving
thanks for making possible the required environment for a writing effort.
It is my hope that this book will stimulate interest in composites by exposing
the plethora of opportunities that lie ahead.
John Delmonte
Glendale, California
CONTENTS
Preface! ix
1. Introduction! 1 .
Historical Perspectives of Metal / Polymer Composites (MPC) / 2
Metal Wire Reinforcement / 5
Metal Fibers/Polymer Fibers / 11
References / 11
2. Production of Finely Divided Metals and Polymers! 12
Production of Metal Powders / 15
Characteristics of Metal Powders / 17
Manufacturing Processes for Metal Powders / 19
Production of Powders from Polymers / 26
Combining Finely Divided Metals and Polymers / 28
References / 38
3. Molding and Casting of Metal! Polymer Composites! 40
Pressure Molding of Plastics Particles / 41
Pressure Molding of Metal Particles / 44
Molding of Combined Metal and Polymer Particles / 49
Similarities of Processing Metal and Plastic Powders / 52
Basic Contributions of Metals and Plastics
to Molded Composites / 52
Encapsulation of Metal Components by Plastic Materials / 54
Metal Inserts / 58
Metal Powders and Liquid Polymers / 60
Miscellaneous Metal Pastes / 69
Interactions between Metal Particles and Polymer Particles / 70
References / 76
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x METAL/POLYMER COMPOSITES
4. Electroconductive Polymer/Metal Composites / 77
Trends in Electroactive Polymers Development / 79
Synthesis of Electroactive Polymer Development / 81
Polyacetylene and Polyt hiophene Developments / 84
Deposition of Metallic Elements by Thermal Decomposition / 85
Metallic Ion Implantation / 86
Photodielectric Analysis / 87
Electrical Conductivity in Metal Filled Composites / 89
Carbon Blacks / 97
References / 99
5. Plastics Coated Metals and Metal Coated Plastics / 102
Reinforced Coatings on Metals / 104
Non-Solvent Mastic Coatings / 105
Plastisols / 108
Dispersion Coatings / 111
Plastic Coating of Metal Structures / 113
Powder Coatings / 115
Sprayed Metal Coatings on Plastics / 117
Electroplating Metals on Plastics Surfaces / 119
Polymer Plating on Conductive (Metal) Substrates / 121
Vacuum Metallizing on Plastics / 123
Ablative and Intumescent Coatings on Metals / 132
References / 133
6. Metal/Polymer Structural Composites /135
Filament Wound Structures / 146
Pultrusion / 148
Polymer Impregnation for Structural Purposes / 153
Low Density Metal Structures / 155
Metal Matrices / 159
Metal/Plastics Combinations / 160
References / 161
7. Radiation Shielding by Metal/Polymer Composites / 163
EMI (Electromagnetic Interferences) and
RFI (Radio Frequency Interferences) / 163
Comparison of Technologies for Shielding / 174
Control of Static Discharge / 178
Plastics Packaging for Food Products / 181
CONTENTS xi
Coaxial Cable Shielding / 183
Shielding against X-Rays and Nuclear Reactors / 184
References / 184
8. Metal/Polymer Composites in Magnetic Components / 187
Magnetic Materials / 189
Developments in Permanent Magnets / 193
Magnetic Material Development for Transformers, Motors
and Generators / 196
Magnetic Materials in Communication / 197
Miscellaneous Magnetic Materials of Polymer/Metal /205
Magnet Wire Enamels / 206
References / 208
9. Micro and Nano Electronic Applications I 210
Semiconductors / 211
Integrated Circuits / 222
Packaging for Electronics / 223
Storage Batteries / 228
Capacitors / 232
Photovoltaic Cells / 234
References / 237
Glossary I 239
Terms Used in Metal Powder and Metal rrocessing / 239
Terms Relating to Plastics/Polymers I 240
Index I 243